Retrofit reinforcing structure addition and method for wind turbine concrete gravity spread foundations and the like

ABSTRACT

A retrofit reinforcing structure addition and method for an existing gravity spread foundation for a wind turbine or the like haying a central pedestal and a spread section is provided. The retrofit structure addition includes a collar formed around the pedestal of the spread foundation. The collar is formed by a shape sustaining member, such as a CMP, placed around the pedestal to define an annular ring between the CMP and the pedestal that is filled with cementitious material. Radial bolts extend horizontally through the collar and into the side of the pedestal. Soil and/or rock anchor bolts extend vertically through the collar, the spread portion of the foundation and into the underlying soil and/or rock substrate. The radial and anchor bolts are post-tensioned to ensure that the cementitious material of the collar remains in compression and the bolts are always in static tension, strengthening the original gravity spread foundation and extending the fatigue life thereof.

This application is a divisional of co-pending U.S. application, Ser.No. 14/870,955 filed Sep. 30, 2015, which claimed priority from U.S.provisional application, Ser. No. 62/060,743 filed Oct. 7, 2014, andalso claims the priority of U.S. provisional application, Ser. No.62/211,158 filed Aug. 28, 2015, and hereby claims the priority thereofto which it is entitled.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention is related to the field of foundations for thesupport of tall, heavy and/or large towers and, more particularly, to aretrofit structure addition and method for reinforcing existing concretegravity spread foundations currently used to support wind turbines andsimilar structures, especially those foundations which have failed orare failing due to long term dynamic fatigue.

Description of the Related Art

Concrete gravity spread foundations are often used to support turbinesin the 1.5 megawatt (MW) range of which there are several thousand inthe U.S. Conventional gravity spread foundation construction relies onreinforced concrete theory and designs which is inappropriate for verydynamic structures like a wind turbine. As a result, these gravityspread foundations are susceptible to long term fatigue failures whichcan result in collapse of the foundation. Such collapses have been knownto occur after as few as 8 to 13 years, well before the expiration ofturbine life which is on the order of 20-25 years or more. Therefore,there is a need for a structure and method by which gravity spreadfoundations may be reinforced to extend their fatigue life well beyondthe turbine life.

SUMMARY OF THE INVENTION

In view of the foregoing, the present invention is directed to aretrofit spread foundation reinforcing structure and method forrestoring the integrity of existing gravity spread foundations andextending the useful life thereof. The retrofit spread foundationreinforcing structure includes a generally cylindrical shape sustainingmember forming an annular cementitious reinforcing collar additionpositioned around the central pedestal and above the expanded base orhorizontal spread section of an original gravity spread foundation. Theshape sustaining member forming the annular collar addition may beembodied as a corrugated metal pipe (CMP) having a diameter greater thanthe diameter of the pedestal. A ring of cementitious material is pouredinto and fills the annular area between the outer side of the centralpedestal and the surrounding shape sustaining member or CMP. The collaraddition thus fully encircles and confines the central pedestal with thebase of the collar pressing against the upper surface of the horizontal,spread section of the already existing spread foundation adjacent to theengaging interface between the bottom of the pedestal and the top of thespread foundation below the pedestal. A plurality of radially extendingbolts extend horizontally through the CMP and cementitious ring of thecollar and into the pedestal of the original foundation. Soil and/orrock anchor bolts are placed to extend vertically from the top of thecementitious ring of the collar addition down through the horizontalspread section and into the underlying soil and/or rock substratebeneath the spread section. The terms “soil and/or rock anchor bolts” or“anchor bolts” are used herein for ease of description and areunderstood by those skilled in the art to include tensioning and/orconnecting anchors embodied as bolts as well as anchors havingtensioning and/or connecting components other than bolts.

The radial bolts and soil and/or rock anchor bolts are post-tensioned inthe manner described in my earlier patents, U.S. Pat. Nos. 7,533,505,5,826,367, 6,672,023, and 7,155,875, all of which are herebyincorporated by reference in their entirety as if fully set forth hereinand sometimes are referred to herein as “my prior patents”, to place theentire foundation under high unit compression loading in both thehorizontal and vertical directions which strengthens the cold jointinterface between the pedestal and the spread section. The soil and/orrock anchor bolts are tightened so as to exceed the maximum upliftexpected from overturning forces of the wind turbine structure on thefoundation. As a result, the entire foundation with the reinforcingcollar addition is able to withstand the various loads with the concretethereof always remaining in compression and the bolts always in statictension.

Accordingly, it is an object of the present invention to provide aretrofit spread foundation reinforcing structure addition and methodthat restores the integrity of existing gravity spread foundations andextends the useful life thereof for many additional years.

Another object of the present invention is to provide a retrofit spreadfoundation reinforcing structure addition in accordance with thepreceding object that includes a reinforcing collar positioned aroundthe central pedestal and above the expanded base or horizontal spreadsection of a gravity spread foundation.

A further object of the present invention is to provide a retrofitspread foundation reinforcing structure addition in accordance with thepreceding objects in which the collar includes a CMP having a diametergreater than an outer diameter of the pedestal to encircle the pedestal,an area between the CMP and the pedestal being filled with cementitiousmaterial to define an annular ring bounded on an outer perimeter by theCMP, the base of the collar resting on, or pressing against, the uppersurface of the horizontal spread section of the foundation.

Yet a further object of the present invention is to provide a retrofitspread foundation reinforcing structure addition in accordance with thepreceding objects that includes post-tensioned soil and/or rock anchorbolts extending vertically from the top of the cementitious annular ringof the collar down through the horizontal spread section of thefoundation and into the underlying soil and/or rock substrate.

Still a further object of the present invention is to provide a retrofitspread foundation reinforcing structure addition in accordance with thepreceding objects that includes post-tensioned radially extending boltsthat extend horizontally through the CMP and annular cementitious collarand into the pedestal of the foundation.

Another object of the present invention is to provide a retrofit spreadfoundation reinforcing structure addition in accordance with thepreceding objects that, when installed on an existing gravity spreadfoundation, places the retrofit portion of the foundation under highunit compression loading through tightening of the anchor bolts so as toexceed the maximum internal tension expected from overturning forces ofthe wind turbine structure on the foundation.

Yet another object of the present invention is to provide a retrofitspread foundation reinforcing structure addition in accordance with thepreceding objects that may be efficiently installed in support ofgravity spread foundations of various configurations.

Still another object of the present invention is to provide a method ofinstalling a retrofit spread foundation reinforcing structure additionin accordance with the preceding objects that includes placement of aCMP around the base of the pedestal of a spread foundation structure andfilling the annular area between the CMP and the pedestal withcementitious material to form a collar that encircles and supports thespread foundation pedestal.

Yet a further object of the present invention is to provide a method ofinstalling a retrofit spread foundation reinforcing structure additionin accordance with the preceding objects in which soil and/or rockanchor bolts are installed vertically through the collar and horizontalspread section of the original foundation and into the underlying soiland/or rock substrate either before or after the cementitious materialis poured into the annular ring between the CMP and the pedestal toreinforce the cold joint engaging interface between the bottom of thepedestal and the upper surface of the central part of the spread sectionbelow the pedestal.

Another object of the present invention is to provide a method ofinstalling a retrofit spread foundation reinforcing structure additionin accordance with the preceding objects in which the anchor bolts arepost-tensioned in a specified sequence to place uniform tension on thefoundation.

These together with other objects and advantages which will becomesubsequently apparent reside in the details of construction andoperation as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings forming a part hereof, whereinlike numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a wind turbine supported on a conventionalgravity spread foundation with the retrofit spread foundationreinforcing structure addition installed thereon in accordance with thepresent invention.

FIG. 2 is a sectional side view of one type of conventional concretegravity spread foundation.

FIG. 3 is a top view of the conventional spread foundation shown in FIG.2.

FIG. 4 is a sectional side view of the conventional spread foundationshown in FIG. 2 with the retrofit spread foundation reinforcingstructure addition installed thereon in accordance with the presentinvention.

FIG. 5 is a top view of the conventional spread foundation reinforcedwith the retrofit spread foundation reinforcing structure addition shownin FIG. 4.

FIG. 5A is a side cutaway view of the collar showing the radial boltsand strand hoops.

FIGS. 6A-6C are top cutaway views of each of three respective layers ofradial bolts as installed according to the retrofit structure and methodof the present invention. FIG. 6D is an isolated top view of theexisting spread foundation tower base flange as shown in relationship tothe radial bolts in FIGS. 6A-6C.

FIGS. 7A and 7B are side views of the three radial bolt layers shown inFIGS. 6A-6C showing the vertical spacing in their layered configurationas when installed.

FIG. 7C is an enlarged view of a radial bolt like those shown in FIGS.7A and 7B.

FIG. 7D is an enlarged view of the coupler for the radial bolts shown inFIGS. 7A-7C.

FIG. 8 shows a soil and/or rock anchor bolt in a partial cutaway view ofone side of the original foundation as retrofitted with the reinforcingstructure addition of the present invention.

FIG. 8A is an enlarged view of the drill hole sleeve and foam fill usedwhen the reinforcing collar is constructed before the anchor bolts arein place.

FIG. 9 is an enlarged view of Detail 9 shown in FIG. 5, without theradial bolts inserted in the radial bolt holes, depicting the manner inwhich the drill holes for the anchor bolts are spaced from the threeradial bolt lavers shown in FIGS. 6A-6C, 7A and 7B and staggeredradially with respect to each other.

FIG. 10 is a top view of the circumference of the retrofit collarshowing the soil and/or rock anchor bolt locations and a preferredsequence order for tensioning the soil and/or rock anchor bolts wheninstalling the collar.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Although only one preferred embodiment of the invention is explained indetail, it is to be understood that the embodiment is given by way ofillustration only. It is not intended that the invention be limited inits scope to the details of construction and arrangement of componentsset forth in the following description or illustrated in the drawings.Also, in describing the preferred embodiments, specific terminology willbe resorted to for the sake of clarity. It is to be understood that eachspecific term includes all technical equivalents which operate in asimilar manner to accomplish a similar purpose.

As shown in FIG. 1, the present invention is directed to a foundationcollar reinforcing structure addition, generally designated by referencenumeral 10, for a conventional existing gravity spread foundationgenerally designated by reference numeral 12. The gravity spreadfoundation 12 includes an expanded base or horizontal spread section 14and a central pedestal 16 upon which a tall and/or heavy tower such as awind turbine, generally designated by reference numeral 18, issupported. The reinforcing structure addition 10 according to thepresent invention includes an annular collar 20, positioned around thecentral pedestal 16 and above the expanded base or horizontal spreadsection 14 of the gravity spread foundation 12 to confine the pedestal.The reinforcing structure addition 10 also exerts compressive force tostrengthen the engaging interface 17 which is a cold joint between thebottom of the pedestal and the top of the central part of the spreadsection under the pedestal 16.

As shown in isolation in FIGS. 2 and 3, the horizontal spread section 14of the existing gravity spread foundation 12 extends outwardly on allsides of the pedestal 16 and may be octagonal as shown in FIG. 3, orother shapes such as circular, square and the like. The tower 18 issecured to the pedestal 16 with a plurality of tower anchor bolts 19that are secured at their lower ends to an embedment ring 21 as is knownin the art and described in my prior patents.

As best shown in. FIG. 4, the collar 20 as positioned around the centralpedestal 16 and above the expanded base or horizontal spread section 14of the gravity spread foundation 12, includes a shape sustaining member,generally designated by reference numeral 15, around its outer perimeterand a ring of cementitious material 24. The shape sustaining outermember 15 is preferably embodied as a corrugated metal pipe (CMP) 22 andwill be referred to as such hereinafter. However, other perimeterforming structures could be used as long as such alternate structuresproperly define the periphery of the ring of cementitious material andprovide for post tensioning of the radial bolts and the soil and/oranchor bolts as discussed herein.

The CMP 22 is generally constructed of a plurality of sections that arebolted together to form a circle or a generally circular ring. Thediameter of the CMP 22 is greater than the diameter of the foundationpedestal 16 and defines the outer perimeter of the ring of cementitiousmaterial 24 which is poured into and fills the annular area, generallydesignated by reference numeral 26, between the outer side of thepedestal 16 and the CMP 22. The collar 20 thus fully encircles thecentral pedestal 16 with the base 28 of the collar 20 resting on theupper surface 30 of the horizontal spread section 14 of the foundation12 (see FIG. 4). As measured from the outer side surface of the pedestalto the CMP, the width or thickness of the cementitious annular collarwhen completed is preferably about 3.5′.

Alternatively, collar 20 does not have to rest directly on the uppersurface 30 of the spread section 14 of the foundation since a layer ofmaterial could be interposed between the collar and the top of thespread section. However, the collar must press against the spreadsection 14 in accordance with the present invention.

The upper surface 81 of the collar bounded by the CMP 22 is preferablyabout level with the upper surface 83 the foundation pedestal The topand bottom of the CMP are preferably cut to form a plane that varies nomore than about +/−2″ from level. The diameter of the CMP is generallybetween about 19′ and about 25′, with a CMP pipe tolerance for out ofroundness of about 3″.

A plurality of radially extending bolts generally designated byreference numeral 40 with strand hoops 44 extend horizontally throughthe CMP 22 and the cementitious material 24 of the annular ring 26 ofthe collar 20 and into the pedestal 16 of the foundation 12 as can beseen in FIGS. 4, 5 and 5A. The upper and lower bolt layers arecircumferentially reinforced by the wire tied strand hoops 44 at about6″ intervals. The innermost ends generally designated by referencenumeral 42 of the radial bolts 40 are received into holes 58 drilledinto the side of the pedestal 16 while the length of the radial boltsthat extends through the cementitious ring 26 is preferably enclosedwithin a sleeve 68 (see FIGS. 7A-7D) to prevent the bolts from bondingwith or adhering to the cementitious material 24 when poured and cured.The radial bolts 40, which anchor the collar 20 to the pedestal 16 ofthe foundation 12, are post-tensioned once the cementitious material hashardened, preferably to about 40% of their ultimate strength.Preferably, washers fitting into the corrugation of the CMP and having aflat outer surface to contact the tensioning nuts are placed against theouter side of the CMP for proper tensioning of the radial bolts, as isknown in the art. Alternatively or additionally, tension plates may beplaced on the inside or the outside of the CMP for the seine purpose.

As shown in FIGS. 6A, 6B and 6C, there are preferably three layers ofradial bolts 40 including a top layer 50, a middle layer 52 and a bottomlayer 54. The radially extending bolts 40 in each layer are onsubstantially the same plane and equidistantly spaced from one anotherlike the spokes of a wheel. As between layers, the bolts in each layerare offset with respect to the bolts in the other layers so that, if thethree layers were placed directly on top of one another, none of thebolts of one layer would be in vertical alignment with the bolts in theadjacent layers. In addition, the radial bolts are positioned, so as notto interfere with the tower anchor bolts 19 in the existing tower baseflange 56 shown in isolation in FIG. 6D.

As shown in FIGS. 7A and 7B, the radial bolt layers 50, 552, 54 arevertically spaced from one another with the area between and around thelayers being filled with the cementitious material 24 of the annularcollar 20. The vertical spacing between the layers is preferably aboutbetween about 12″ and about 18″, and more preferably about 18″. Thediameter of the radial bolts 40 is preferably between about 1″ and about2″.

The radial bolts 40 are preferably inserted into core holes 58 that aredrilled into the side of the central pedestal of the existing gravityspread foundation to a depth of between about 36″ to about 60″, andpreferably about 54″. The diameter of the radial bolt core holes 58descends in increments as the drilling approaches the center of thepedestal. The core hole at the CMP and inward for about 3″ has adiameter of about 2.5″. For the next approximately 21″ the core hole hasa diameter of about 2″. The final 30′ or so of the hole has a diameterof about 1.75″. The innermost ends 42 of the radial bolts 40 arepreferably secured within the drilled foundation core holes 58 with anadhesive such as epoxy 41 that is inserted into the holes duringinstallation of the radial bolts. Preferably the part 62 of the radialbolts that extends through the collar is covered with a sleeve 68 havinga length of between about 15″ and about 26″, and preferably about 21″.

As shown in the embodiment of FIGS. 7C and 7D, the radial bolts includetwo parts. The collar embedded part 62 of the radial bolts 40 ispreferably joined with the foundation embedded sleeved part 60 of theradial bolts 40 by a coupler 64. The coupler 64 is preferably enclosedwithin a sleeve 66 having a diameter of about 2.5″ and a length of about4″. The collar portion 62 of the radial bolts is preferably betweenabout 4′ and about 5′ in length, and more preferably about 4.5′, andpreferably is also encased within a sleeve 68 to prevent engagement ofthe radial bolt with the cementitious material. After tensioning, theouter ends 70 of the radial bolts extend approximately 12″ beyond theouter perimeter of the collar CMP 22, although the length of theprojecting ends 70 may be greater or lesser as needed for the particularfoundation being reinforced.

As shown in. FIGS. 4, 5 and 8, a plurality of soil and/or rock anchorbolts 80 are placed to extend vertically from the upper surface 81 ofthe cementitious annular ring 26 of the collar 20 down through thehorizontal spread section 14 of the gravity spread foundation and intothe underlying soil and/or rock substrate 90. The soil and/or rockanchor bolts 80, or anchors, are between about 25′ and about 40′ inlength, and preferably are about 30′ in length. The upper end of theanchor bolts is preferably enclosed within a sleeve 82 to preventengagement of the bolt with the cementitious material in a “no bond”area 97 (see FIG. 8). The extent of the “no bond” area 97 is defined bythe sleeve 82 that is preferably at least 10′ in length. The sleeve 82extends substantially through the height of the collar 20, through thes′read section 14 of the foundation and about two to three feet into theunderlying soil and/or rock substrate 90. In the embodiment shown, thedistance from the upper surface 81 of the collar to the bottom 101 ofthe spread section is approximately 7.5′, with the 10′ sleeve extendingabout an additional 2.5′ into the underlying substrate. The lower bondedarea 85 of the anchor bolts, below the horizontal spread section 14 andextending into the underlying soil and/or rock substrate 90, isgenerally between about 14′ and about 30′ in length, and is preferablyabout 19′ in length. The total embedment length of the soil and/or rockanchor bolts 80, including the bonded 85 and “no bond” 97 areas, isgenerally on the order of between about 24′ and about 39′, andpreferably is about 29′. Following, construction of the collar, the soiland/or rock anchor bolts are post-tensioned in the “no bond” area toabout 60% of their ultimate strength.

If the cementitious material of the retrofit collar addition is to bepoured before the soil and/or rock anchor bolts are drilled, tubular PVCsleeves 88 about 6″ in diameter are placed vertically in the excavatedregion for the anchor bolts (see FIGS. 8 and 8A) and secured for theconcrete pour. Once the cementitious material is set, the soil and/orrock anchor bolts are drilled down through the hollow center of the PVCsleeves 88 and, to prevent water entry, the upper 3″ of the drill holesleeve 88 is filled with foam 91 as shown in FIG. 8A.

The anchor bolts are drilled in holes 100 in between adjoining radialbolt holes 58 in each radial bolt layer as shown in FIG. 9 such that theanchor bolts 80 and the radial bolts 40 inserted in the holes 58 do notinterfere with one another. The diameter of the drill hole 100 for therock anchor bolts is between about 4″ and about 6″, and is preferablyabout 5.5″. When the anchor bolts are in place in the drill holes 100,grout is poured into the annular space 71 around the lower end of theanchor bolts in the bonded area 85 and in the annular space 73 betweenthe outer surface of the sleeves 82 and the inner surface of the PVCtubes 88 in the “no-bond” area 97. The anchor bolts 80 arepost-tensioned in the manner described in my prior patents to place theentire collar 20 and spread foundation 12 under high unit compressionloading.

A preferred sequence for tensioning of the anchor bolts is shown in FIG.10. As shown, the first and second bolts to be tensioned are on oppositesides of the collar, and the third and fourth bolts to be tensioned areon opposite sides that are 90° out from the first and second bolts. Thesoil and/or rock anchor bolts 80 are tensioned in opposing pairs as setforth in FIG. 10 to ensure even and uniform tension on the collar. Thesoil and/or rock anchor bolts may be part of rock anchors, soil anchors,helical anchors and the like, depending upon the makeup of theunderlying support substrate.

The soil and/or rock anchor bolts, in conjunction with the collar thatsupports and contains the pedestal, serve to reinforce and strengthenthe cold joint engaging interface 17 between the bottom of the pedestaland the top of the spread section under the pedestal. With the radialbolts horizontally securing the collar to the pedestal, and the anchorbolts providing a vertical connection of the collar to the spreadsection, the reinforcing addition of the present invention effectivelyprovides compressive force on the engaging interface 17 to increase thestrength, stiffness and load bearing capacity of the spread foundation.

A preferred construction sequence for constructing the reinforcingcollar according to the present invention as follows:

-   -   1) construct temporary turbine supports (temporary guys or        brackets);    -   2) excavate soil from atop the spread foundation for        construction of retrofit collar; pile soil adjacent to the        retrofit excavation;    -   3) expose rebar at radial bolt and rock anchor locations;    -   4) core two 2″ diameter holes 24″ long into foundation pedestal        for each bolt;    -   5) expand the 2″ core to 2.5″ for the first 3″ of the core;    -   6) drill 1.75″ hole with percussion drill beyond the 2″ cored        hole to within about 30″ of the center of the pedestal for each        radial bolt; radial bolt holes extend about 1″ beyond the end of        the 0.5″ radial bolt;    -   7) inject approximately 30 cubic inches of epoxy into the back        of the holes drilled for the radial bolts;    -   8) insert into each radial bolt hole the 1.5″ grade 75 all        thread radial bolt with PVC sleeve sealed at the end of the PVC        to the bolt with epoxy;    -   9) turn the couplers onto the bolt;    -   10) turn into the coupler the sleeved outer 4.5′ of 1.5″ grade        75 all thread bolt with wire tied strand hoops on the upper and        lower radial bolt circles;    -   11) insert multi-plate CMP sections over radial bolts and bolt        CMP sections together;    -   12) place half oval washers over radial bolts into the CMP        depressions; turn nuts onto the radial bolts and snug against        the washers;    -   13) place 6″ PVC tubes vertical for rock anchors to be drilled        through and secure for concrete pour;    -   14) pour concrete retrofit;    -   15) drill and install rock anchors, centralized, and grouted in        place in the bond and “no bond” areas, upper ends of said rock        anchors being enclosed within a sleeve in the “no bond” area;    -   16) post-tension radial bolts;    -   17) install rock anchor plates grouted in place; and    -   18) post-tension rock anchors.

The steps to be undertaken with respect to a wind turbine installed onan existing gravity spread foundation before and after installing thereinforcing collar according to the present invention are as follows:

-   -   1) coordinate retrofit foundation work with electrical work;    -   2) verify turbine de-energized before any work is begun;    -   3) provide backup power generator to allow for control of the        wind turbine in an idling condition;    -   4) disconnect cables from transformers;    -   5) temporarily remove and store the transformer for        reinstallation;    -   6) demolish the transformer concrete pad, if necessary to remove        the pad;    -   7) temporarily remove the existing stairs and store for        reinstallation;    -   8) demolish the existing stair landing concrete slab, if        necessary;    -   9) locate grounding wires and protect during excavation; if        necessary reroute or disconnect and reinstall grounding wires as        needed;    -   10) control water that enters the excavation and the turbine        pad;    -   11) remove anchor bolt caps and grout from caps and bolt        threads;    -   12) relax the tower anchor bolts and thoroughly clean the        threads;    -   13) maintain tower anchor bolt nuts in a tight and snug        condition; tighten with impact wrench to snug condition;    -   14) repair or reinstall ground wires as required;    -   15) route or reroute conduit as required;    -   16) remove the temporary supports after the retrofit foundation        has been constructed complete in place and concrete cured;    -   17) construct new support slab and conduit vault for        transformer, if required;    -   18) restore anchor bolt tension;    -   19) reinstall tower access stair; and    -   20) reinstall transformer and connect the electrical cables.

The anchor bolts are tightened so as to exceed the maximum internaltension expected from overturning forces of the wind turbine structureon the foundation. As a result, the entire foundation with thereinforcing collar is able to withstand the various loads with theconcrete thereof always remaining in compression and both the radial andthe soil and; or rock anchor bolts always in static tension. As aresult, the reinforcing structure addition according to the presentinvention can extend the life of an original gravity spread foundationthat would otherwise have failed or is failing by at least an additional20-25 years

The present invention is also directed to a method of modifying anexisting gravity spread reinforced concrete foundation, increasing thefoundation stiffness and the rotational stiffness of the entire windturbine structure. Modifying the existing gravity spread foundation alsoincreases the turbine resistance to overturn and extends the foundationlife by at least an additional 25 years, which is the expected turbinelife.

The present invention also includes a method of modifying an existingshallow gravity spread foundation to a deep foundation, alleviating anumber of potential failures found in connection with shallowfoundations. These failures can include overturn, frost heave, erosionand scour, differential settlement, tilting, foundation/soil gapping,flooding, vertical seismic acceleration, horizontal seismicacceleration, liquefaction, collapsible soils and expansive soils,

Finally, the present invention provides a method of restoring integrityand continued use to a failed or failing concrete gravity spreadfoundation. As evident from the foregoing description, the retrofitreinforcement structure addition including the collar with radial boltsand soil and/or rock anchor bolts extending horizontally and verticallythrough the collar, respectively, serves to reinforce, strengthen andprovide compressive force upon the engaging interface between the bottomof the pedestal and the top of the spread section under the pedestal.When restored and supported by the retrofit reinforcement structureaddition of the present invention, the useful life of an otherwisefailed or failing gravity foundation is extended for at least anadditional 25 years which is the expected turbine life period.

The foregoing descriptions and drawings should be considered asillustrative only of the principles of the invention. The invention maybe configured in a variety of shapes and sizes and is not limited by thedimensions of the preferred embodiment. Numerous applications of thepresent invention will readily occur to those skilled in the art.Therefore, it is not desired to limit the invention to the specificexamples disclosed or the exact construction and operation shown anddescribed. Rather, all suitable modifications and equivalents may beresorted to, falling within the scope of the invention.

1. A method of installing a retrofit spread foundation reinforcingstructure addition onto an existing concrete gravity spread foundationhaving a central pedestal and a spread section and supporting a tower orwind turbine, the retrofit spread foundation reinforcing structureaddition including an annular cementitious collar having a shapesustaining member at its outer perimeter, a plurality of radial boltsextending horizontally through the collar and into the central pedestal,and a plurality of vertically oriented soil and/or rock anchor boltsextending downwardly through the collar and the spread section of thefoundation, the method comprising the steps of: drilling a plurality ofhorizontally extending core holes in the sides of the pedestal for theradial bolts; inserting the radial bolts into said horizontallyextending core holes in the sides of the pedestal; encircling thepedestal with the shape-sustaining member to define a generally annularring around the central pedestal of the foundation; placing sleevemembers in a vertical orientation in the generally annular ring for thesoil and/or rock anchor bolts to be drilled through and securing thesleeve members for concrete pour; pouring concrete into the generallyannular ring between the shape-sustaining member and the centralpedestal; drilling and installing soil and/or rock anchor bolts,generally centralized in said sleeve members; post-tensioning the radialbolts; and post-tensioning the soil and/or rock anchor bolts.
 2. Themethod as set forth in claim 1, further comprising, before the step ofinserting radial bolts into said horizontally extending core holes inthe sides of the pedestal, the step of injecting epoxy or similaradhesive into inner ends of said horizontally extending core holes tosecure the inner ends of the radial bolts.
 3. The method as set forth inclaim 1, wherein the step of encircling the pedestal with theshape-sustaining member includes inserting multi-plate corrugated metalpipe (CMP) sections over the radial bolts and bolting the CMP sectionstogether to form said shape sustaining member.
 4. The method as setforth in claim. 3, further comprising the steps of, after bolting theCMP sections together, placing half oval washers over the radial boltsinto depressions in the CMP, turning nuts onto the radial bolts andsnugging the nuts against the washers.
 5. The method as set forth inclaim 1, wherein said step of drilling and installing soil and/or rockanchor bolts generally centralized in said sleeve members includesgrouting said anchor bolts place.
 6. The method as set forth in claim 1,wherein said sleeve members are PVC tubes.
 7. The method as set forth inclaim 1, further comprising, before the step of drilling a plurality ofhorizontally extending core holes in the sides of the pedestal for theradial bolts, the steps of: constructing temporary turbine supports; andexcavating soil from atop the spread section of the foundation forconstruction of the retrofit collar.
 8. A method of modifying anexisting gravity spread reinforced concrete foundation having a pedestaland a spread section supporting a wind turbine structure to increasefoundation stiffness, rotational stiffness of the wind turbinestructure, and turbine resistance to overturn, said method comprisingthe steps of confining the pedestal with a reinforcing structure thatsurrounds the pedestal, and reinforcing the pedestal and an engaginginterface between the pedestal and the spread section using thereinforcing structure.
 9. The method as set forth in claim 7, whereinsaid steps of confining and reinforcing include the steps of: drilling aplurality of horizontally extending core holes in the sides of thepedestal for a plurality of horizontally extending radial bolts;inserting sleeved radial bolts into said horizontally extending coreholes in the sides of the pedestal; encircling the pedestal with ashape-sustaining member to define an annular ring between an outer sidesurface of the pedestal and the shape-sustaining member, said sleevedradial bolts extending through said annular ring and saidshape-sustaining member; filling the annular ring with cementitiousmaterial to form a collar, said sleeved radial bolts being embedded insaid collar with ends thereof extending beyond an outer surface of saidshape-sustaining member, a base of the collar pressing on an uppersurface of the spread section of the foundation; and post-tensioning thehorizontally extending radial bolts at the extending ends thereof. 10.The method as set forth in claim 9, further comprising, after the stepof inserting sleeved radial bolts into said horizontally extending coreholes in the sides of the pedestal, the step of securing the inner endsof the radial bolts with epoxy or similar adhesive.
 11. The method asset forth in claim 9, wherein, before said step of filling the annularring with cementitious material, said step of reinforcing includes thesteps of placing PVC tubes substantially vertically in said annularspace and securing said tubes for pour of said cementitious material.12. The method as set forth in claim 11, further comprising, afterpouring and curing of said cementitious material, the step of drilling aplurality of vertically extending rock and/or soil anchor bolts throughsaid tubes in said collar and into an underlying rock and/or soilsubstrate beneath said spread section, upper ends of said anchor boltsextending above an upper surface of said collar for post-tensioningthereof.
 13. The method as set forth in claim 9, wherein said step ofdrilling a plurality of horizontally extending core holes in the sidesof the pedestal includes drilling holes at three vertically spacedlevels such that radial bolts fitted in said holes form an uppergenerally horizontal radial bolt laver, a middle generally horizontalradial bolt layer and a lower generally horizontal radial bolt layer,radial bolts in said upper, middle and lower layers being verticallyoffset from one another.
 14. The method as set forth in claim 13,further comprising the step of the circumferentially reinforcing theupper and lower bolt layers with wire-tied strand hoops at about 6″intervals.
 15. A retrofit reinforcing structure addition for an existingspread foundation that has a central pedestal and a horizontal spreadsection, the retrofit structure comprising: collar encircling thecentral pedestal of the spread foundation, a base of the collar pressingon an upper surface of the horizontal spread section of the foundation;a plurality of radial bolts extending horizontally from an outerperimeter of the collar, through the collar and into the pedestal; and aplurality of soil and/or rock anchor bolts extending vertically from anupper surface of the collar, through the horizontal spread section andinto an underlying soil and/or rock substrate below the spread section.16. The retrofit spread foundation reinforcing structure addition as setforth in claim 15, wherein said soil and/or rock anchor bolts and saidradial bolts are post-tensioned.
 17. The retrofit spread foundationreinforcing structure addition as set forth in claim 15, wherein saidcollar includes a shape sustaining outer member and a ring ofcementitious material, said shape sustaining outer member having adiameter greater than an outer diameter of the pedestal to define agenerally annular area between the shape sustaining outer member and thecentral pedestal, cementitious material being poured into said annulararea and hardened to form said ring of cementitious material.
 18. Theretrofit spread foundation reinforcing structure addition as set forthin claim 17, wherein said shape sustaining outer member is a corrugatedmetal pipe (CMP).
 19. The retrofit spread foundation reinforcingstructure addition as set forth in claim 17, wherein said plurality ofradial bolts includes three layers of radially extending boltsvertically spaced from one another, the upper and lower bolt layersbeing circumferentially reinforced by wire tied strand hoops at about 6″intervals.